Artificial-stone slab, shingle, and plate and composition for making same.



106. COMPOSITIONS,

COATING OR PLASTIC.

UNITED sTATEs LAUHHEIU? PATENT OFFICE.

WILLIA SANGEBlOF PASSAIC, NEW JERSEY, ASSIGNOR, BY MESNE ASSIGNMENTS,

TO A BESTO S SLATE ROOFING MANUFACTURING COMPANY, INCORPORATED.

ARTIFICIAL-STONE SLAB, SHINGLE, AND PLATE AND COMPOSITION FOR MAKINGSAME.

No Drawing.

To all whom it may concern:

Be it known that I, WILLIAM SANGER, a citizen of the German Empire, anda resident of Passaic, in the county of Passaic and State of New Jersey,have invented certain new and useful Improvements in Artificial- StoneSlabs, Shingles, and Plates and Composition for Making Same, of whichthe following is a specification.

This invention has reference to a novel process of making artificialstone slabs, shingles, plates and the like. It pertains particularly toanovel process of producing slabs and shingles for roofing purposes of acomposition consisting essentially of asbestos fiber, hydraulic bindingcement and anhydrous silica or as it is scientifically called silicondioxid or silicium dioxid, and some water.

Heretofore compositions of this kind have} been prepared from asbestosfiber and? cements with additions of special watersilica which is mixedwith Portland cement,

etc. The sodium nitrate certainly-is useless in an artificial stoneproduct. Other compositions result in artificial stone products whichsuifer from the defect of effiorescence.

If the mixture contains calcium oxid and magnesium oxid then thefinished product blossoms out under atmospheric influences.

For instance Ca (OH) -CO =CaCO -|H O whereby efiiorescence is produced.

Specification of Letters Patent.

Patented Apr. 24, 1917.

the precious metals. cement canonly be kept in suspension by great bulksof water for a limited period of time as the specifically heaviercomponents act differently from the lighter ones. Great bulks of watermake the production of an article tedious and increase the costunnecessarily.

It is the special purpose of the present invention to avoid thedescribed defects and to produce artificial stone, slabs, shingles, or[plates by means of a very simple and inex- {pensive process which alsoresults in a superior article. This has been primarily atg tained bypreparing a composition of hydraulic bindin cement asbestos fiber and 14 an IVC ru M l 5 rous s1 10a 1 ages. t pre vent s gfljorescence becauseit combines into calcium silicate or ma esium silicate with comaoundslike Cal; anm nea y a ways presen in any cemen 1 ions matter andwhich are acted upon by the atimospheric carbonic acid gas CO under theiformation of calcium carbonate or magnegsium carbonate. These latteringredients particularly have a very detrimental effect gupon pressedcementitious materials inasmuch as they cause cracks within the finishedgoods and also decrease their tensile strength to a very high degree.The reci 1- tated silica preferably employed tlierefore impar s auniform character to the mass and gives the finished product thenecessary elasticity at an increased tensile strength. The action ofatmospheric water upon the finished articles will have no detrimentalefiect whatever upon them, but on the contrary the uncombined silica inthe presence of water will further combine with the bases i mentionedabove while the simpler silicates.

Anotheri may be transformed into more complicated For these reasons.

1e a1 1011 o a ypresents various a vancomposition speaks of colloidalcement. silica compounds thus causing a further.

This expression appears not to be apprepriate for a cement or similarmineral substance of composite character. Such composite materials cannot be brought 1nto a colloidal condition like gums, starch, gelatin orthe ductile precious metals, since they never will be glueor jellylikebecause their composite character implies different specific gravities.Composite substances are not uniform as to physical condition and,accordingly can not acquire the state of be ng perfectly colloidal likegelatln or ductlle like silification. The anhydrous silica remains inthe finished shingles unchanged throughout except at the surface where asubsequent exposure to the atmosphere partly produces a silification ofthe surface portion.

-" The silica outside is only temporarily hydrated because it combineswith lime and forms the insoluble calcium silicate.

The invention is carried into effect in sub- I stantially the followingmanner:

. An intimate mixture is prepared of hydgaulic bind ing cement, asbestosand anhytion which a drous silica with a small quantity of water.

The plastic mass obtalnd is then put into molds adapted to give thefinished article the desired shape. In case of shingles I prefer toproduce them each with a rectangular and a slanting longitudinal surfacefor the purpose of producing what the architects call a shadow lineeffect on the roof and to facilitate the laying. The mass, while in thehermeticall sealed mold, is subjected to the pressure 0 compressed air.The shingles thus dehydrated and molded are subsequently sub'ected to,hi draulic pressure 1 highly pressed article is treated with steam toeffect the silification in e sur ace pory resultsifi "the restraint ofsllicate of calcium by combining with the lime of the cement.

The addition of anhydrous silica also presents the advantage of bindingcaustic bases such as lime which may occur in the cement or the mass.This in turn results in a better hardening of the product and increasedtensile strength and the properties of being water and fire proof arealso increased.

The proportions in which the various components are admixed may varywithin reasonable limits especially on account of variations in thecompositions of the cements. One formula which gives good results formost products is substantially as follows:

About 80 arts of cement are mixed with 15 parts of nely' disintegratedasbestos and about 5 parts of anhydrous silica. A plastic mass isprepared from this dry mixture with only about twice its weight ofwater. The plastic mass is then worked up into shingles, plates, orslabs etc. in the manner herein described.

I claim as my invention:

1. A composition of matter for producing artificial stone slabs,shingles, plates and the like consisting of cement, asbestos fiber,chemically active precipitated anhydrous silica, and water, the saidsilica being adapted to effect the silification of the bases containedin the cement. r

2. A composition of matter for producing artificial stone, slabs,shingles, plates and the like consisting of cement, finely dividedasbestos fiber, chemically active preci itated anhydrous silica, andwater, the sai silica .being adapted to effect the silification of thebases contained in the cement and to increase the strength and hardnessof the composition in the course of time by forming insoluble silicateunder the influence of atmospheric moisture and carbonic acid gas.

3. A composition of matter for producing copies of this patent may beobtained for artificial stone slabs, shingles, plates and the likeconsisting of cement, fine asbestos fiber, chemically activeprecipitated anhydrous silica and about twice the weight of the dry massof water, the said silica being adapted to effect the silification ofthe bases of the cement.

4. A composition of matter for producing artificial stone slabs,shingles, plates and the like consisting of cement, fine asbestos fiber,chemically active precipitated anhydrous silica and about twice theweight of the dry mass of water, the said silica being adapted to effectthe silification of the bases of the cement throughout. the compositionand of its surface portion by steam.

5. A composition of matter for producing artificial stone slabs,shingles, plates and the like consistin of hydraulic binding cement,fine asbestos ber, chemically active precipitated anhydrous silica, andwater, the said silica and free earthy basic oxids occurring in thesurface portion of the composition being adapted to be hydrated by steamand to form insoluble earthy silicates from the by drated substances.

6. A composition of matter for producing artificial stone articlesconsisting of about 80 parts of hydraulic binding cement, about 15 partsof finely divided asbestos fiber, about 5 parts of chemically activeprecipitated anhydrous silica, and about twice the weight of the drymass of water, the said silica being adapted to effect the h dration ofthe silica and basic earthy oxi s of the surface portion and to forminsoluble earthy silicate.

7. As a novel product of manufacture an artificial stone articlecomposed of hydraulic binding. cement, fine asbestos fiber, precipitatedanhydrous silica, and in which insoluble silicates'of the earthyalkaline bases are produced in the surface portion when ex-' posed toatmospheric moisture and carbonic acid as.

8. s a novel product of manufacture an artificial stone articlecomprising about 80 parts of hydraulic binding cement, about 15 parts offinely divided asbestos fiber, about 5 parts of precipitated anhydroussilica, and in which insoluble silicates of the earthy alkaline basesare produced in the surface portion when exposed to the action ofatmospheric moisture and carbonic acid gas.

Signed at New York, N. Y., this 24th day of August, 1915.

WILLIAM SANGER. Witnesses:

HERMAN J. RUBENSTEIN, LILLEY E. SCHMIDT.

five cents each, by addressing the "Commissioner of Patents, Washington,D. 0. A

